Device and method for splicing shielded wire cables

ABSTRACT

A wire cable assembly, such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables spliced together. The center conductors are joined together and enclosed in an inner insulator. The shield conductors of the cable are joined by an electrically conductive sleeve enclosing the inner insulator and attached to the shield conductors of the shielded wire cables. The sleeve separates the outer insulating layers of the shielded wire cables. The sleeve is encased by an outer insulator that is sealed to the outer insulating layers of the shielded wire cables. A method of splicing shielded wire cables together is also presented.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a national stage application under 35 U.S.C. § 371of PCT Application Number PCT/US13/67440 having an international filingdate of Oct. 30, 2013, which designated the United States, said PCTapplication claiming the benefit of U.S. Provisional Patent ApplicationNo. 61/720,474 filed Oct. 31, 2012 and U.S. Provisional PatentApplication No. 61/731,020 filed Nov. 29, 2012. The entire disclosuresof both of these applications are hereby incorporated herein byreference.

TECHNICAL FIELD OF THE INVENTION

The invention generally relates to a splicing device and a method forjoining shielded wire cables.

BACKGROUND OF THE INVENTION

Shielded wire cables typically include an insulated center conductor anda separate insulated shield conductor surrounding the center conductorinsulation. The shield conductor may consist of a braided wire mesh,metal foil, or metalized film. The cables typically have a secondinsulation layer covering the shield conductor. Shielded wire cableshave been long used for communications systems, such as in cabletelevision transmission lines. Shielded wire cables are also finding usein high voltage applications in electric and hybrid electric vehicles.When shielded wire cables are spliced together, there is usually a needto electrically connect the shield conductors of the spliced cables aswell as the center conductor, in order to maintain electrical continuityof the shield conductors. Interconnecting the shield conductors may becomplicated because the shield conductors must be cut back from thespliced ends of the cable in order to join the center conductors.Interconnecting the shield conductors may be further complicated in aone-to-many splicing configuration, sometimes referred to as a Y-splice.

The subject matter discussed in the background section should not beassumed to be prior art merely as a result of its mention in thebackground section. Similarly, a problem mentioned in the backgroundsection or associated with the subject matter of the background sectionshould not be assumed to have been previously recognized in the priorart. The subject matter in the background section merely representsdifferent approaches, which in and of themselves may also be inventions.

BRIEF SUMMARY OF THE INVENTION

In accordance with one embodiment of this invention, a wire harnessassembly is provided. The wire harness assembly includes a firstshielded wire cable having a first core conductor at least partiallyaxially surrounded by a first shield conductor which is at leastpartially axially surrounded by a first insulative jacket, a secondshielded wire cable having a second core conductor at least partiallyaxially surrounded by a second shield conductor which is at leastpartially axially surrounded by a second insulative jacket, and a thirdshielded wire cable having a third core conductor at least partiallyaxially surrounded by a third shield conductor which is at leastpartially axially surrounded by a third insulative jacket, wherein thefirst, second and third core conductors form a directly joined portionand the first, second, and third shield conductors are physicallyseparated one from another. The wire harness assembly also includes aconductive sleeve defining a longitudinal axis and a first axial passageenclosing a portion of the first, second, and third shield conductorsand defining a first contact attached to the first shield conductor, asecond contact attached to the second shield conductor, and a thirdcontact attached to the third shield conductor, wherein the first,second, and third insulative jackets are separated one from another andwherein enclosed portions of the of the first, second, and third shieldconductors are substantially parallel to the longitudinal axis. The wirecable assembly further includes an outer insulator sealably engaging thefirst, second, and third insulative jackets and enclosing the conductivesleeve.

The wire harness assembly may include an inner insulator disposed withinthe first axial passage and defining a second axial passage enclosingthe joined portion of the first, second, and third core conductors. Theinner insulator and the sleeve may have a generally elliptical crosssection. A portion of the second axial passage may be narrowed such thatonly a single shielded cable may be disposed within the portion of thesecond axial passage. The sleeve may define a crimping wing configuredto form the first contact and the sleeve may define a U-shaped slotconfigured to form the second and third contact. The first, second, andthird contact may each define a hole configured to allow the injectionof solder paste into the interior of the first, second, and thirdcontacts. The wire harness assembly may further include a plurality offerrules attached to each of the first, second, and third shieldconductors, wherein the first, second and third contacts are attached toat least one of the plurality of ferrules. At least one ferrule in theplurality of ferrules may be formed of solder.

In accordance with another embodiment of the wire harness assembly, thefirst, second, and third contact may be attached to the first, second,and third outer conductor respectively by a plurality of ferrules. Thesleeve may include a first sleeve portion configured to be joined to asecond sleeve portion and the inner insulator may include a first innerinsulator portion configured to be joined to a second inner insulatorportion.

In yet another embodiment of the invention, a method of splicingshielded wire cables together is provided. The method includes the stepsof providing a first shielded wire cable having a first core conductorat least partially axially surrounded by a first shield conductor whichis at least partially axially surrounded by a first insulative jacket,providing a second shielded wire cable having a second core conductor atleast partially axially surrounded by a second shield conductor which isat least partially axially surrounded by a second insulative jacket,providing a third shielded wire cable having a third core conductor atleast partially axially surrounded by a third shield conductor which isat least partially axially surrounded by a third insulative jacket,providing a shield defining a longitudinal axis, a first axial passage,and a first, second, and third contact, said shield formed of aconductive material, and providing an inner insulator defining a secondaxial passage, said inner insulator formed of a dielectric material. Themethod also includes the steps of joining the first center conductor tothe second center conductor and the third center conductor, disposingthe joined first, second, and third inner conductors within the secondaxial passage, disposing the inner insulator and the first, second, andthird shield conductors within the first axial passage, wherein theportions of the of the first, second, and third shield conductorsdisposed within the inner insulator are substantially parallel to thelongitudinal axis, and separating the first, second, and thirdinsulative jackets one from another. The method further includes thesteps of attaching the first contact to the first shield conductor, thesecond contact to the second shield conductor, and the third contact tothe third shield conductor, thereby providing a conductive path betweenthe first, second, and third shield conductors, providing an outerinsulator formed of a nonconductive material, disposing the shieldwithin the outer insulator, and sealably engaging the outer insulator tothe first, second, and third insulative jackets, thereby enclosing theshield within the outer insulator. The joined first, second, and thirdinner conductors may be slidably disposed within the second axialpassage and the first, second, and third shield conductors may beslidably disposed within the first axial passage.

Where the first, second, and third contact each define a hole, themethod may include the steps of injecting solder paste into the interiorof the first, second, and third contacts through the holes definedtherein and heating the solder paste until it reflows, thereby solderingthe first, second, and third contacts to the first, second, and thirdshield conductors respectively. The method may optionally include thesteps of providing a first, second, and third ferrule; attaching thefirst, second, and third ferrule to the first, second, and third shieldconductors respectively, crimping the first, second, and third ferruleto the first, second, and third contacts respectively, thereby attachingthe first, second, and third contacts to the first, second, and thirdshield conductors respectively.

Where the sleeve includes a first sleeve portion and a second sleeveportion, the method may additionally include the step of joining thefirst sleeve portion to the second sleeve portion, thereby disposing thejoined first, second, and third inner conductors within the second axialpassage.

Where the inner insulator includes a first inner insulator portion and asecond inner insulator portion, the method may further include the stepof joining the first inner insulator portion to the second innerinsulator portion, thereby disposing the inner insulator and the first,second, and third shield conductors within the first axial passage.

Where the outer insulator further includes an end cap configured tosealably engage the outer insulator and at least one shielded wirecable, the method may also include the steps of sealably engaging theend cap with the at least one shielded wire cable and sealably engagingthe end cap with the outer insulator, thereby enclosing the shieldwithin the outer insulator.

Further features and advantages of the invention will appear moreclearly on a reading of the following detailed description of thepreferred embodiment of the invention, which is given by way ofnon-limiting example only and with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The present invention will now be described, by way of example withreference to the accompanying drawings, in which:

FIG. 1 is a schematic diagram of a prior art electrical load connectionscheme;

FIG. 2 is a schematic diagram of an electrical load connection scheme inaccordance with a first and second embodiment;

FIG. 3 is an illustration of a wire harness assembly having a centerconductor splice connection in accordance with the first embodiment;

FIG. 4 is a perspective view of a wire harness assembly having an innerinsulator pre-loaded on a shielded wire cable in accordance with thefirst embodiment;

FIG. 5 is a perspective view of a wire harness assembly having the innerinsulator enclosing the center conductor splice connection in accordancewith the first embodiment;

FIG. 6 is semi-transparent perspective view of the inner insulator ofthe wire harness assembly of FIG. 5 enclosing the center conductorsplice connection in accordance with the first embodiment;

FIG. 7 is a cut-away view of the inner insulator of the wire harnessassembly of FIG. 6 enclosing the center conductor splice connection inaccordance with the first embodiment;

FIG. 8 is a perspective view of a wire harness assembly having a shieldpre-loaded on the shielded wire cable in accordance with the firstembodiment;

FIG. 9 is a perspective view of the shield the wire harness assembly ofFIG. 8 enclosing the inner insulator in accordance with the firstembodiment;

FIG. 10 is a cut-away view of the shield of the wire harness assembly ofFIG. 9 enclosing the inner insulator in accordance with the firstembodiment;

FIG. 11A is a perspective view of crimping a contact of the wire harnessassembly of FIG. 10 to a shield conductor in accordance with the firstembodiment;

FIG. 11B is a top close up view of the contacts and wire separation ofthe wire harness assembly of FIG. 10 in accordance with the firstembodiment;

FIG. 12 is a perspective view of an outer insulator enclosing the shieldof the wire harness assembly of FIG. 10 in accordance with the firstembodiment;

FIG. 13 is a perspective view of the wire harness assembly in accordancewith the first embodiment;

FIG. 14 is an exploded perspective view of a wiring harness assembly inaccordance with a second embodiment;

FIG. 15 is perspective view of an inner insulator of the wiring harnessassembly of FIG. 14 in accordance with the second embodiment;

FIG. 16 is a perspective view of an assembly of the inner insulators ofthe wiring harness assembly of FIG. 14 in accordance with the secondembodiment;

FIG. 17 is a perspective view of an assembly of inner insulators of thewiring harness assembly of FIG. 14 disposed within a portion of a sleevein accordance with the second embodiment;

FIG. 18 is a perspective view of an assembly of inner insulators of thewiring harness assembly of FIG. 14 enclosed within a sleeve inaccordance with the second embodiment;

FIG. 19 is a perspective view of an assembly of fastening devices tocontacts defined by the sleeve of the wiring harness assembly of FIG. 14in accordance with the second embodiment;

FIG. 20 is perspective view of a sleeve of the wiring harness assemblyof FIG. 14 in accordance with the second embodiment;

FIG. 21 is a perspective view of an assembly of a shield assembly withinan outer insulator of the wiring harness assembly of FIG. 14 inaccordance with the second embodiment;

FIG. 22 is a perspective view of an assembly of end caps to shieldedwire cables of the wiring harness assembly of FIG. 14 in accordance withthe second embodiment;

FIG. 23 is a perspective view of an assembly of the end caps to theouter insulator of the wiring harness assembly of FIG. 14 in accordancewith the second embodiment;

FIG. 24 is a perspective view of the outer insulator of the wiringharness assembly connected to another outer insulator of another wiringharness assembly in accordance with the second embodiment;

FIG. 25A is a side view of two wiring harness assemblies disposed withina wiring conduit in accordance with the second embodiment;

FIG. 25B is an end view of two wiring harness assemblies disposed withina wiring conduit in accordance with the second embodiment;

FIGS. 26A, 26B, and 26C are views of a wiring harness assembly includingfour shielded wire cables in accordance with a third embodiment; and

FIGS. 27A and 27B are flow charts of a method of splicing shielded wirecables together in accordance with the first and second embodiment.

DETAILED DESCRIPTION OF THE INVENTION

Described herein are devices and a methods for splicing two or moreshielded wire cables together. The devices and methods may be used tosplice shielded wire cables with a single center conductor or multiplecenter connectors. The devices and methods described herein may be usedto splice together two shield wire cables, for example to repair a cutcable. The devices and methods described herein may also be used tosplice one shielded wire cable to two or more shielded wire cables toform a Y-splice. The devices and methods described herein may be usedfor splicing a variety of shielded wire cables types, for exampleshielded wire cables for communication transmissions, such as RG-59cable, or high voltage shielded wire cables designed for electrical orhybrid electrical vehicles.

FIG. 1 illustrates a prior art scheme for connecting electrical loads 1to a battery pack 2, such as in an electric vehicle. Each electricalload 1 requires a pair of high voltage shielded wire cables (positive 3and negative 4 polarity) running from the battery pack 2 to theelectrical load 1 and a separate fuse 5 protecting each of the circuits.

FIG. 2 illustrates a non-limiting example of a scheme for connectingelectrical loads 11 to a battery pack 12, such as in an electric vehicleby splicing together a pair of positive cables 13 and a pair of negativecables 14 using the devices and methods presented herein. The inventorsdiscovered that several circuits may be combined and share a single fuse15, for example because the electrical loads 11 are not usedconcurrently. The electrical loads 11 may also be connected to acontroller 22 that enables the electrical loads 11 to operate one at atime so that they are not used concurrently or the controller maymonitor the current used by each of the electrical loads 11 and controleach of the electrical loads 11 so that the total current used by theelectrical loads 11 is less than the current rating required to blow, oropen, the fuse 15. The inventors realized that a pair of high voltageshielded wire cables 13, 14 to these electrical loads 1 could be splicedtogether as shown in FIG. 2 with a shielded cable splice device 20,hereinafter device 20, that connects the center conductors 17 of theshielded wire cables 13, 14 while maintaining isolation and continuityof the shield conductors (not shown) of the shielded wire cables 13, 14,thereby reducing the length of shielded wire cable 13, 14 required tointerconnect the electrical loads 11 to the battery pack 12, thusreducing shielded wire cable 13, 14 cost, weight, packaging space, andwire routing complexity for the wiring harness. Because multipleelectrical loads 11 can share a single fuse 15, The number of fusedcircuits in the battery pack 12 could also be reduced; further reducingcost and complexity of the battery pack 12 by reducing the number offuses 15 and cable connectors 16 compared with the prior art scheme ofFIG. 1.

FIG. 3 illustrates a non-limiting example of three high voltage shieldedwire cables a first shielded cable 110, a second shielded cable 112, anda third shielded cable 114 that have been spliced together. A centerconductor 116, 118, 120 of each of the shielded cables 110, 112, 114 hasbeen joined by a sonic welding process to form a connection 122.Portions of the outer insulation layers 124, 126, 128, shield conductors130, 132, 134, and inner insulation layers 136, 138, 140 have beenremoved from the center conductors 116, 118, 120 prior forming theconnection 122. Alternatively, other processes well known to thoseskilled in the art, such as soldering or crimping the conductors withina conductive sleeve may be used to form the connection 122. Anadditional portion of each of the shield conductors 130, 132, 134 may beremoved or cut way to provide adequate voltage creepage distance 142 toprevent a leakage current between the center conductors 116, 118, 120and the shield conductors 130, 132, 134, thereby exposing the innerinsulation layers 136, 138, 140 of the shielded cables 110, 112, 114.Additionally, conductive ferrules 144, 146, 148 may be mechanically andelectrically attached to the shield conductors 130, 132, 134 to providea more durable electrical connection to the shield conductors 130, 132,134. The ferrules may be a closed or barrel-type ferrule that isattached to the shield conductors by crimping or soldering prior toforming the connection 122 or the ferrules may be an open or clip-typeferrule that can be attached to the shield conductors by crimping afterforming the connection 122. The ferrules may be formed of a soldermaterial that is heated, for example by induction heating, until theferrules reflow and join the contacts to the shield conductors. Theferrules may comprise an inner ferrule that is disposed between theshield conductor and the inner insulation layer and an outer ferrulethat is disposed over the shield conductor. Materials and methods usedto attach the conductive ferrules 144, 146, 148 to the shield conductors130, 132, 134 are well known to those skilled in the art.

FIGS. 4 through 15 illustrate a non-limiting example of a process offorming a shielded cable assembly 150 having both the center conductors116, 118, 120 and the shield conductors 130, 132, 134 of three shieldedwire cables 110, 112, 114 spliced together according to a firstembodiment. The embodiment illustrated here is configured to splicethree shielded wire cables 110, 112, 114 together in a Y-spliceconfiguration. However, alternative embodiments may be envisioned thatare configured to splice just two shielded wire cables together orsplice more than three shielded wire cables together.

As illustrated in FIG. 4, the wire cable assembly 150 includes an innerinsulator 152 formed of dielectric material. The dielectric material maybe a polymer material, such as glass-filled polyamide (commonly known bythe trade name NYLON) or polybutylene terephthalate (PBT). The innerinsulator 152 may be formed using an injection molding process or otherplastic forming processes well known to those skilled in the art. Theinner insulator 152 is designed to enclose the exposed portion of theconnection 122 and a portion of the exposed inner insulation layers 136,138, 140 of the shielded cables 110, 112, 114.

The inner insulator 152 defines an axial passage 154, hereafter referredto as a channel 154 that is designed to accommodate the connection 122and the joined shielded wire cables 110, 112, 114. As shown in FIGS. 5and 6, the inner insulator 152 may then be slid over the single shieldedcable 110 along the longitudinal axis A in the direction 156 over theconnection 122, leaving the shield conductors 130, 132, 134 exposed.

As shown in FIG. 7, the channel 154 of the inner insulator 152 maydefine shoulders 158 to provide a positive stop against the two joinedinner conductors 118, 120 and ensure proper positioning of the innerinsulator 152 relative to the connection 122 and the exposed shieldconductors 130, 132, 134. The inner insulator 152 may be designed with asymmetrical shape so that the shoulders 158 contact the two joined innerconductors 118, 120 regardless of the orientation of the inner insulator152 when the inner insulator 152 is placed on the single shielded wirecable 110.

As shown in FIG. 8, the wire cable assembly 150 further includes asleeve 160 formed of conductive material that defines an axial passage161, hereafter referred to as a cavity 161 along a longitudinal axis A.The conductive material used to form the sleeve 160 is preferably acopper alloy, such as 425 brass and may be tin coated for corrosionresistance. As shown in FIG. 9, the sleeve 160 may be slid along thelongitudinal axis A in the direction 156 over the inner insulator 152,disposing the inner insulator within the cavity 161. The sleeve 160defines contacts 162, 164, 166 that are designed to be crimped intomechanical and electrical contact with the shield conductors 130, 132,134. The sleeve 160 may define a generally elliptical cross section. Asused herein, generally elliptical cross section means that thecircumferential shape of the sleeve varies by no more than ±10% fromthat of an elliptical cross section.

As shown in FIG. 10, the sleeve 160 may define lock features 168 thathold the sleeve 160 in proper position over the inner insulator 152. Thelock features 168 may define a pair of ramp structures 170 wherein oneof the ramp structures 170 is designed to deflect as the sleeve 160slides along the longitudinal axis A over the lock in the direction 156and then snap back into place, thereby capturing the inner insulator 152between the lock features 168. Alternatively, the sleeve may be slidalong the longitudinal axis in the direction opposite of direction 156.The sleeve 160 may be designed with a symmetrical shape so that the lockfeatures 168 secure the sleeve 160 to the inner insulator 152 regardlessof the orientation when the sleeve 160 is placed on the single shieldedwire cable 110. Other locking features well known to those skilled inthe art may alternately be utilized to secure the sleeve 160 in placeover the inner insulator 152. The shoulders 158 of the inner insulator152 and the lock features 168 of the sleeve 160 cooperate to locate theexposed shield conductors 130, 132, 134 or ferrules relative to thecontacts 162, 164, 166. This provides the benefit of more consistentconnections between the contacts and the shield conductors in themanufacturing process.

As illustrated in FIG. 11, the contacts 162, 164, 166 are crimped to theshield conductors 130, 132, 134 or ferrules attached to the shieldconductors 130, 132, 134, by applying a mechanical force to provide amechanical and electrical connection between the sleeve 160 and theshield conductors 130, 132, 134 and provide electrical continuitybetween all of the shield conductors 130, 132, 134. According to theillustrated example, the sleeve defines a plurality of U-shaped slots172 forming bands 174, 176, 178, 180 that are configured to deform whencrimped to secure the sleeve to the shield conductors or ferrules. Thebands 178, 180 forming contacts 164, 166 are crimped by applying forceto the central portion of the bands so that central portion of the bandspush the shielded wire cables 112, 114 apart and ensuring that theinsulating layers of shielded cables are separated, that is are not inphysical contact with one another. The portions of the first, second,and third shield conductors that are enclosed within the shield aresubstantially parallel to the longitudinal axis A. This provides asplice connection that is basically in-line which may be easier topackage within a location with limited space, such as within anautomobile. As used herein, substantially parallel means±10° ofabsolutely parallel. In an alternative embodiment, the sleeve 160 maydefine conventional crimping wings that connect to the shield conductorsor ferrules by wrapping about them and crimping. The crimping wings areconfigured to separate the insulating layers of the shielded cables. Inanother alternative embodiment, the contacts 162, 164, 166 may beelectrically and mechanically connected to the shield conductors 130,132, 134 by soldering or other processes well known to those skilled inthe art rather than crimping.

As illustrated in FIG. 12, an outer insulator 182 formed on a dielectricmaterial may be placed over the sleeve 160. The outer insulator 182 maybe formed of a thermoplastic heat shrink tubing. Suitable compositionsand sources of heat shrink tubing are well known to those skilled in theart. The outer insulator 182 may also be preloaded onto the blunt cutsingle shielded wire cable 110 prior to forming the connection 122. Theheat shrink tubing may then be heated using methods well known to thoseskilled in the art to sealably engage the outer insulation layers 124,126, 128 of at least one of the shielded wire cables 110, 112, 114 andenclose the sleeve 160 as shown in FIG. 13. As used herein, sealablyengaged means that the outer insulator 182 will resist contaminants,such as dust, dirt, or fluids, from entering between the outerinsulation layers 124, 126, 128 and the outer insulator 182. It does notmean that it provides a hermetic seal. Alternatively, the outerinsulator 182 may comprise or may consist of a conformal coating 184,such as a silicone-based material, applied over the sleeve 160 andshielded wire cables 110, 112, 114. The inventors have discovered thatseparation of the insulating layers of the shielded cables by the sleeveprovides the benefit of improved sealing between the outer insulator andthe shielded cables. Without subscribing to any particular theory ofoperation, the outer insulator or the sealant within the outer insulatoris able to contact the entire circumference of the outer insulationlayers 126, 128, thus avoiding any gaps or voids that may be created ifthe outer insulation layers 126, 128 were not separated or weretouching.

FIGS. 14 through 25B illustrate a non-limiting example of a process offorming a shielded cable assembly 150 having both the center conductors116, 118, 120 and the shield conductors 130, 132, 134 of three shieldedwire cables 110, 112, 114 spliced together according to a secondembodiment. The embodiment illustrated here is configured to splicethree shielded wire cables 110, 112, 114 together in a Y-spliceconfiguration. However, alternative embodiments may be envisioned thatare configured to splice just two shielded wire cables together orsplice more than three shielded wire cables together.

FIG. 14 illustrates another non-limiting example of a wire cableassembly 250. The reference numbers in this embodiment for identicalelements are the same as the previously described embodiment and thereference numbers of similar elements are 100 higher. The embodimentillustrated here is configured to splice three shielded wire cables 110,112, 114 together by connecting the center conductor 116, 118, 120 ofeach of the shielded cables 110, 112, 114 to form a connection 122 asshown in FIG. 3 and described supra. However, this embodiment may beused to splice four shielded wire cables together and other embodimentsmay be envisioned that are configured to splice just two shielded wirecables together or splice more than four shielded wire cables together.

The shielded cable assembly 250 includes a first inner insulator 252Aformed of dielectric material and a second inner insulator 252B formedof a dielectric material. The dielectric material may be a polymermaterial, such as glass filed NYLON or PBT. The first inner insulator252A and the second inner insulator 252B may be formed of the samedielectric material or they may be formed of different dielectricmaterials. The first inner insulator 252A and the second inner insulator252B may be formed using an injection molding process or other plasticforming processes well known to those skilled in the art.

The first inner insulator 252A is designed to be joined to the secondinner insulator 252B and when the first inner insulator 252A and thesecond inner insulator 252B are joined, they enclose the connection 122and a portion of the exposed inner insulation layers 136, 138, 140 eachof the shielded wire cables 110, 112, 114.

As shown in FIG. 15, the first inner insulator 252A and the second innerinsulator 252B may define a pair of interconnected channels 254A, 254Bto secure the joined shielded wire cables 110, 112, 114 within the firstinner insulator 252A and the second inner insulator 252B. The firstinner insulator 252A and the second inner insulator 252B may alsoinclude a set of mating tapered posts 253 and indentations 255 in orderto facilitate alignment of the first inner insulator 252A and the secondinner insulator 252B when they are assembled around the shielded wirecables 110, 112, 114. The first inner insulator 252A and the secondinner insulator 252B may be designed with a hermaphroditic shape so thata single inner insulator 252 may be used for both the first innerinsulator 252A and the second inner insulator 252B. In the example shownhere, the joined inner insulator 252 may have an unused portion of thechannel 254A.

As illustrated in FIG. 18, the wire cable assembly 250 further includesa sleeve 260 formed of conductive material that defines a longitudinalaxis A. The conductive material used to form the sleeve 260 ispreferably a copper alloy, such as 425 brass and may be tin coated forcorrosion resistance. The sleeve 260 defines contacts 262, 264, 266 thatare designed to be in mechanical and electrical contact with the shieldconductors 130, 132, 134 of the shielded wire cables 110, 112, 114. Thecontacts 262, 264, 266 protrude from the sleeve 260 and form an arcuateshape configured to conform to the shield conductors 130, 132, 134 orferrules. As illustrated in FIG. 19, the contacts 262, 264, 266 may besecured to the shield conductors 130, 132, 134 by a separate fasteningdevice 284, such as a band or sleeve that may be crimped around thecontacts 262, 264, 266.

Alternatively, as shown in FIG. 20, the contacts 262, 264, 266 maydefine crimp wings 286 that have an arcuate shape prior to being crimpedaround the shield conductors 130, 132, 134 of each of the shielded wirecables 110, 112, 114. The contacts 262, 264, 266 are designed to contactthe shield conductors 130, 132, 134 to provide an electrical connectionbetween the shield conductors 130, 132, 134 of each of the shielded wirecables 110, 112, 114. The contacts 262, 264, 266 may also be designed tomechanically secure the shielded wire cables 110, 112, 114 to the sleeve260 and provide strain relief to the joined center conductor 116, 118,120 of the cables.

Returning to FIG. 18, the sleeve 260 is designed to enclose the firstinner insulator 252 and to define cable portals for each of the shieldedwire cables 110, 112, 114 to exit the sleeve 260. The sleeve 260 may bemade up of a first sleeve 260A that defines a set of contacts 262A,264A, 266A and a second sleeve 260B that defines another set of contacts262B, 264B, 266B. The first sleeve 260A is configured to enclose theinner insulator when mated with the second sleeve 260B. Features may beincluded in the joining surfaces of the first sleeve 260A and the secondsleeve 260B to reduce electrical resistance. Alternatively, the firstsleeve 260A and the second sleeve 260B may be secured together usingconductive threaded fasteners. The first sleeve 260A and the secondsleeve 260B may be designed with a hermaphroditic shape so that a singlepart may be used for both the first sleeve 260A and the second sleeve260B. In the example shown here, there may be an unused portal andcontact. The contacts 164, 166 push the shielded wire cables 112, 114apart and ensuring that the insulating layers of shielded cables areseparated, that is are not in physical contact with one another. Theportions of the first, second, and third shield conductors that areenclosed within the shield are substantially parallel to thelongitudinal axis. This provides a splice connection that is basicallyin-line which may be easier to package within a location with limitedspace, such as within an automobile.

As illustrated in FIG. 21, the wire cable assembly 250 may furtherinclude an outer insulator 282 formed of a nonconductive material anddefining a cavity 261 that is configured to partially enclose the sleeve260. The wire cable assembly 250 also includes a first end cap 288 thatis designed to sealably engage one of the shielded wire cables 110 andsealably engage the outer insulator 282 and a second end cap 290 that isdesigned to sealably engage the other two shielded wire cables 112, 114.The end caps and outer insulator 282 are designed to provideenvironmental protection to the spliced cables by keeping contaminantssuch as dust, dirt, water, and other fluids away from the joined innerconductors, joined inner insulator, and sleeve 260. The outer insulator282 and end caps may be formed of a polymer material, such as NYLON orPBT. The end caps may also include a sealing element 292 formed ofcompliant material, such as silicone rubber. The inventors havediscovered that separation of the insulating layers of the shieldedcables by the sleeve provides the benefit of improved sealing betweenthe sealing element 292 and the shielded cables. Without subscribing toany particular theory of operation, the sealing element 292 is able tocontact the entire circumference of the outer insulation layers 126,128, thus avoiding any gaps or voids that may be created if the outerinsulation layers 126, 128 were not separated or were touching.

As best illustrated in FIG. 23, the outer insulator 282 may include amale attachment feature 294 and a female attachment feature 296 that aredesigned to interconnect multiple outer insulators 282 as shown in FIG.24. These attachment features 294, 296 may simplify assembly of thewiring harnesses by maintaining a spatial relationship between the outerinsulators and provide a more robust wiring harness assembly becausethere is less likely to be vibrational contact between outer insulatorsthat may degrade the outer insulators 282 over time.

As illustrated in FIG. 25, multiple wire cable assemblies 250 may bepositioned in a staggered arrangement so that the wire cable assemblies250 may be enclosed with a wiring conduit 298. Staggering the wire cableassemblies 250 may offer the benefit of a smaller conduit and thereforerequire less packaging space for the resulting wiring harness.

Alternative embodiments may be envisioned by combining various featuresof the two embodiments illustrated in FIGS. 4-25. For example, the innerinsulator 152 and the sleeve 160 may comprise two separate portions,similar to the inner insulator 252 and sleeve 260. As another example,the sleeve 160 may define contacts that protrude from the sleeve thatare attached to the shield conductors or ferrules by a separatefastening device, such as a band or sleeve that may be crimped aroundthe contacts, similarly to the sleeve 260.

FIG. 26 illustrates a non-limiting method 300 of splicing shielded wirecables together. The method 300 includes the following steps.

STEP 310, PROVIDE A FIRST, SECOND, AND THIRD SHIELDED WIRE CABLE,includes providing a first shielded wire cable having a first coreconductor at least partially axially surrounded by a first shieldconductor which is at least partially axially surrounded by a firstinsulative jacket, providing a second shielded wire cable having asecond core conductor at least partially axially surrounded by a secondshield conductor which is at least partially axially surrounded by asecond insulative jacket, and providing a third shielded wire cablehaving a third core conductor at least partially axially surrounded by athird shield conductor which is at least partially axially surrounded bya third insulative jacket as shown in FIG. 3.

STEP 312, PROVIDE A SHIELD DEFINING A LONGITUDINAL AXIS, A FIRST AXIALPASSAGE, AND A FIRST, SECOND, AND THIRD CONTACT, includes providing ashield that defines a longitudinal axis, a first axial passage, a firstcontact, a second contact, and a third contact. The shield is formed ofa conductive material. The shield may be formed of one piece as shown inFIG. 9 or multiple pieces as shown in FIG. 14.

STEP 314, PROVIDE AN INNER INSULATOR DEFINING A SECOND AXIAL PASSAGEincludes providing an inner insulator defining a second axial passage.The inner insulator is formed of a dielectric material. The innerinsulator may be formed of one piece as shown in FIG. 5 or multiplepieces as shown in FIG. 14.

STEP 316, JOIN THE FIRST CENTER CONDUCTOR TO THE SECOND CENTER CONDUCTORAND THE THIRD CENTER CONDUCTOR, includes joining the first centerconductor to the second center conductor and to the third centerconductor to form a mechanical and electrical connection between thecenter conductors as shown in FIG. 3. The center conductors may bejoined by sonic welding, soldering, or other methods of joining wiresknown to those skilled in the art. The inner insulator and the ferrulesmay be preloaded onto the shielded cables prior to joining the centerconductors.

STEP 318, DISPOSE THE JOINED FIRST, SECOND, AND THIRD INNER CONDUCTORSWITHIN THE SECOND AXIAL PASSAGE, includes disposing the connectionincluding the joined first, second, and third inner conductors withinthe second axial passage, or channel, of the inner insulator as shown inFIGS. 6 and 15. The joined first, second, and third inner conductors maybe slidably disposed within the second axial passage as shown in FIG. 6.

STEP 320, DISPOSE THE INNER INSULATOR AND THE FIRST, SECOND, AND THIRDSHIELD CONDUCTORS WITHIN THE FIRST AXIAL PASSAGE, includes disposing theinner insulator and the first, second, and third shield conductorswithin the first axial passage as shown in FIGS. 8-9 and 17-18. Theportions of the first, second, and third shield conductors that aredisposed within the inner insulator are substantially parallel to thelongitudinal axis. The inner insulator and the first, second, and thirdshield conductors may be slidably disposed within the first axialpassage as shown in FIGS. 8-9.

STEP 322, SEPARATE THE FIRST, SECOND, AND THIRD INSULATIVE JACKETS ONEFROM ANOTHER, includes separating the first, second, and thirdinsulative jackets one from another. This may be accomplished by theconnection of the first, second, and third shield conductors to thecontacts as shown in FIGS. 11 and 19.

STEP 324, ATTACH THE FIRST CONTACT TO THE FIRST SHIELD CONDUCTOR, THESECOND CONTACT TO THE SECOND SHIELD CONDUCTOR, AND THE THIRD CONTACT TOTHE THIRD SHIELD CONDUCTOR, includes attaching the first contact to thefirst shield conductor, the second contact to the second shieldconductor, and the third contact to the third shield conductor, therebyproviding a conductive path between the first, second, and third shieldconductors. The contacts may be attached to the shield conductors bycrimping wings, ferrules, soldering, or other methods known to thoseskilled in the art.

STEP 326, DISPOSE THE SHIELD WITHIN THE OUTER INSULATOR, includesdisposing the shield within the outer insulator as illustrated in FIGS.12 and 21-22.

STEP 328, SEALABLY ENGAGE THE OUTER INSULATOR TO THE FIRST, SECOND, ANDTHIRD INSULATIVE JACKETS, includes sealably engaging the outer insulatorto the first, second, and third insulative jackets, thereby enclosingthe shield within the outer insulator as illustrated in FIGS. 13 and22-23.

Method 300 may further include the following optional steps.

Prior to step 324, method 300 may include STEP 330, PROVIDE A FIRST,SECOND, AND THIRD FERRULE, which includes providing a first, second, andthird ferrule.

Following step 330, method 300 may include STEP 332, ATTACH THE FIRST,SECOND, AND THIRD FERRULE TO THE FIRST, SECOND, AND THIRD SHIELDCONDUCTORS RESPECTIVELY, which includes attaching the first, second, andthird ferrule to the first, second, and third shield conductorsrespectively.

Following step 330, method 300 may include STEP 334, CRIMP THE FIRST,SECOND, AND THIRD FERRULE TO THE FIRST, SECOND, AND THIRD CONTACTSRESPECTIVELY, which includes crimping the first, second, and thirdferrule to the first, second, and third contacts respectively, therebyattaching the first, second, and third contacts to the first, second,and third shield conductors respectively.

Prior to step 324, method 300 may include STEP 336, INJECT SOLDER PASTEINTO THE INTERIOR OF THE FIRST, SECOND, AND THIRD CONTACTS THROUGH THEHOLES DEFINED THEREIN, which includes injecting solder paste into theinterior of the first, second, and third contacts through holes definedby the first, second, and third contacts.

Following step 336, method 300 may include STEP 338, HEAT THE SOLDERPASTE UNTIL IT REFLOWS, which includes heating the solder paste until itreflows, thereby soldering the first, second, and third contacts to thefirst, second, and third shield conductors respectively.

Prior to step 320, method 300 may include STEP 340, JOIN A FIRST SLEEVEPORTION TO A SECOND SLEEVE PORTION, which includes joining the firstsleeve portion to the second sleeve portion, thereby disposing thejoined first, second, and third inner conductors within the second axialpassage, wherein the sleeve includes a first sleeve portion and a secondsleeve portion.

Prior to step 318, method 300 may include STEP 342, JOIN A FIRST INNERINSULATOR PORTION TO A SECOND INNER INSULATOR PORTION, which includesjoining the first inner insulator portion to the second inner insulatorportion, thereby disposing the inner insulator and the first, second,and third shield conductors within the first axial passage, wherein theinner insulator includes a first inner insulator portion and a secondinner insulator portion.

Following step 326, method 300 may include STEP 344, SEALABLY ENGAGE ANEND CAP WITH AT LEAST ONE SHIELDED WIRE CABLE, which includes joiningsealably engaging the end cap with the at least one shielded wire cable,wherein the outer insulator further includes an end cap configured tosealably engage the outer insulator and at least one shielded wirecable.

Following step 344, method 300 may include STEP 346, SEALABLY ENGAGE THEEND CAP WITH THE OUTER INSULATOR, which includes engaging the end capwith the outer insulator, thereby enclosing the shield within the outerinsulator.

Accordingly, a wire cable assembly 150, 250 and a method 500 for joiningtogether shielded wire cables having a center conductor and a shieldconductor insulated from and surrounding the center conductor t areprovided. The wire cable assembly 150, 250 may be used in the wiringharnesses of electric and hybrid electric vehicles. In this application,one wire cable assembly 150, 250 may be used to connect the positiveterminal of the battery pack 12 to two or more electrical loads 11 andanother wire cable assembly 150, 250 may be used to connect the negativeterminal of the battery pack 12 to the same two or more electrical loads11. The splices in the wire cable assemblies may be offset from eachother along the run of the cable to minimize packaging space requiredfor the wiring harness. Connecting the battery pack 12 to multipleelectrical loads 11 with the wire cable assembly 150, 250 provides thebenefit of decreased cost due to a reduced length of cable required andreduced packaging space required while maintaining electrical continuityof the shield conductors 130, 132, 134 in the wiring harness.

While this invention has been described in terms of the preferredembodiments thereof, it is not intended to be so limited, but ratheronly to the extent set forth in the claims that follow. Moreover, theuse of the terms first, second, etc. does not denote any order ofimportance, but rather the terms first, second, etc. are used todistinguish one element from another. Furthermore, the use of the termsa, an, etc. do not denote a limitation of quantity, but rather denotethe presence of at least one of the referenced items.

We claim:
 1. A wire harness assembly comprising: a first shielded wirecable having a first core conductor at least partially axiallysurrounded by a first shield conductor which is at least partiallyaxially surrounded by a first insulative jacket; a second shielded wirecable having a second core conductor at least partially axiallysurrounded by a second shield conductor which is at least partiallyaxially surrounded by a second insulative jacket; a third shielded wirecable having a third core conductor at least partially axiallysurrounded by a third shield conductor which is at least partiallyaxially surrounded by a third insulative jacket, wherein the first,second and third core conductors are directly joined to form a joinedportion and the first, second, and third shield conductors arephysically separated one from another; a conductive sleeve defining alongitudinal axis and a first axial passage enclosing a portion of thefirst, second, and third shield conductors and defining a first contactattached to the first shield conductor, a second contact attached to thesecond shield conductor, and a third contact attached to the thirdshield conductor, wherein the first, second, and third insulativejackets are separated one from another and wherein enclosed portions ofthe of the first, second, and third shield conductors are substantiallyparallel to the longitudinal axis, wherein the sleeve defines a crimpingwing configured to form the first contact and wherein the sleeve definesa U-shaped slot configured to form the second and third contact; and anouter insulator sealably engaging the first, second, and thirdinsulative jackets and enclosing the conductive sleeve.
 2. The wireharness assembly according to claim 1, further comprising an innerinsulator disposed within the first axial passage and defining a secondaxial passage enclosing the joined portion of the first, second, andthird core conductors.
 3. The wire harness assembly according to claim2, wherein the inner insulator and the sleeve have a generallyelliptical cross section.
 4. The wire harness assembly according toclaim 2, wherein a portion of the second axial passage is narrowed suchthat only a single shielded cable may be disposed within the portion ofthe second axial passage.
 5. The wire harness assembly according toclaim 2, wherein the first, second, and third contact are attached tothe first, second, and third shield conductors respectively by aplurality of ferrules.
 6. The wire harness assembly according to claim5, wherein the sleeve includes a first sleeve portion configured to bejoined to a second sleeve portion.
 7. The wire harness assemblyaccording to claim 6, wherein the inner insulator includes a first innerinsulator portion configured to be joined to a second inner insulatorportion.
 8. The wire harness assembly according to claim 1, wherein thefirst, second, and third contact each define a hole configured to allowinjection of solder paste into the interior of the first, second, andthird contacts.
 9. The wire harness assembly according to claim 8,further comprising a plurality of ferrules attached to each of thefirst, second, and third shield conductors, wherein the first, second,and third contacts are attached to at least one of the plurality offerrules.
 10. The wire harness assembly according to claim 9, wherein atleast one ferrule in the plurality of ferrules is formed of solder. 11.A system, comprising: a battery pack having a first terminal and asecond terminal; a first and second electrical load electrically coupledto the battery pack; and a first wire harness assembly which comprises:a first shielded wire cable, a second shielded wire cable, and a thirdshielded wire cable, wherein first, second, and third core conductors ofthe first, second, and third shielded wire cable are directly joined andwherein the first shielded wire cable is connected to the firstterminal, the second shielded wire cable is connected to the firstelectrical load, and the third shielded wire cable is connected to thesecond electrical load; a second wire harness assembly which comprises:a fourth shielded wire cable, a fifth shielded wire cable, and a sixthshielded wire cable, wherein the fourth, fifth, and sixth coreconductors of the fourth, fifth, and sixth shielded wire cable aredirectly joined and wherein the fourth shielded wire cable is connectedto the second terminal via a fusible link, the fifth shielded wire cableis connected to the first electrical load, and the sixth shielded wirecable is connected to the second electrical load; and a controller incommunication with the first and second electrical load and configuredto control the first and second electrical load so that a currentflowing through the fourth shielded wire cable is less than a thresholdrequired to open the fusible link.
 12. The system of claim 11, whereineach pair of first and second wire harness assemblies are connected toonly one fusible link.
 13. A method of splicing shielded wire cablestogether, comprising the steps of: providing a first shielded wire cablehaving a first core conductor at least partially axially surrounded by afirst shield conductor which is at least partially axially surrounded bya first insulative jacket; providing a second shielded wire cable havinga second core conductor at least partially axially surrounded by asecond shield conductor which is at least partially axially surroundedby a second insulative jacket; providing a third shielded wire cablehaving a third core conductor at least partially axially surrounded by athird shield conductor which is at least partially axially surrounded bya third insulative jacket; providing a shield defining a longitudinalaxis, a first axial passage, and a first, second, and third contactconfigured to be electrically connected to the first, second, and thirdshield conductor respectively, said shield formed of a conductivematerial; providing an inner insulator defining a second axial passage,said inner insulator formed of a dielectric material; joining the firstcore conductor to the second core conductor and the third coreconductor; disposing the joined first, second, and third innerconductors within the second axial passage; disposing the innerinsulator and the first, second, and third shield conductors within thefirst axial passage, wherein portions of the of the first, second, andthird shield conductors disposed within the inner insulator aresubstantially parallel to the longitudinal axis; separating the first,second, and third insulative jackets one from another; attaching thefirst contact to the first shield conductor, the second contact to thesecond shield conductor, and the third contact to the third shieldconductor, thereby providing a conductive path between the first,second, and third shield conductors; providing an outer insulator formedof a nonconductive material; disposing the shield within the outerinsulator; and sealably engaging the outer insulator to the first,second, and third insulative jackets, thereby enclosing the shieldwithin the outer insulator, wherein the joined first, second, and thirdinner conductors are slidably disposed within the second axial passage.14. The method of claim 13, further comprising the steps of: providing afirst, second, and third ferrule; and attaching the first, second, andthird ferrule to the first, the second, and the third shield conductorsrespectively.
 15. The method of claim 13, wherein the first, second, andthird contact each define a hole, the method further comprising thesteps of: injecting solder paste into the interior of the first, second,and third contacts through the hole defined therein; and heating thesolder paste until it reflows, thereby soldering the first, second, andthird contacts to the first, second, and third shield conductorsrespectively.
 16. The method of claim 13, further comprising the stepsof: providing a first, second, and third ferrule; and crimping thefirst, the second, and the third ferrule to the first, second, and thirdcontacts respectively, thereby attaching the first, second, and thirdcontacts to the first, second, and third shield conductors respectively.17. The method of claim 16, wherein the sleeve includes a first sleeveportion and a second sleeve portion, the method further comprising thestep of: joining the first sleeve portion to the second sleeve portion,thereby disposing the joined first, second, and third inner conductorswithin the second axial passage.
 18. The method of claim 16, wherein theinner insulator includes a first inner insulator portion and a secondinner insulator portion, the method further comprising the step of:joining the first inner insulator portion to the second inner insulatorportion, thereby disposing the inner insulator and the first, second,and third shield conductors within the first axial passage.
 19. A methodof splicing shielded wire cables together, comprising the steps of:providing a first shielded wire cable having a first core conductor atleast partially axially surrounded by a first shield conductor which isat least partially axially surrounded by a first insulative jacket;providing a second shielded wire cable having a second core conductor atleast partially axially surrounded by a second shield conductor which isat least partially axially surrounded by a second insulative jacket;providing a third shielded wire cable having a third core conductor atleast partially axially surrounded by a third shield conductor which isat least partially axially surrounded by a third insulative jacket;providing a shield defining a longitudinal axis, a first axial passage,and a first, second, and third contact configured to be electricallyconnected to the first, second, and third shield conductor respectively,said shield formed of a conductive material; providing an innerinsulator defining a second axial passage, said inner insulator formedof a dielectric material; joining the first core conductor to the secondcore conductor and the third core conductor; disposing the joined first,second, and third inner conductors within the second axial passage;disposing the inner insulator and the first, second, and third shieldconductors within the first axial passage, wherein portions of the ofthe first, second, and third shield conductors disposed within the innerinsulator are substantially parallel to the longitudinal axis;separating the first, second, and third insulative jackets one fromanother; attaching the first contact to the first shield conductor, thesecond contact to the second shield conductor, and the third contact tothe third shield conductor, thereby providing a conductive path betweenthe first, second, and third shield conductors; providing an outerinsulator formed of a nonconductive material; disposing the shieldwithin the outer insulator; and sealably engaging the outer insulator tothe first, second, and third insulative jackets, thereby enclosing theshield within the outer insulator, wherein the inner insulator and thefirst, second, and third shield conductors are slidably disposed withinthe first axial passage.
 20. The method of claim 19, further comprisingthe steps of: providing a first, second, and third ferrule; andattaching the first, second, and third ferrule to the first, the second,and the third shield conductors respectively.
 21. The method of claim19, wherein the first, second, and third contact each define a hole, themethod further comprising the steps of: injecting solder paste into theinterior of the first, second, and third contacts through the holedefined therein; and heating the solder paste until it reflows, therebysoldering the first, second, and third contacts to the first, second,and third shield conductors respectively.
 22. The method of claim 19,further comprising the steps of: providing a first, second, and thirdferrule; and crimping the first, the second, and the third ferrule tothe first, second, and third contacts respectively, thereby attachingthe first, second, and third contacts to the first, second, and thirdshield conductors respectively.
 23. The method of claim 22, wherein thesleeve includes a first sleeve portion and a second sleeve portion, themethod further comprising the step of: joining the first sleeve portionto the second sleeve portion, thereby disposing the joined first,second, and third inner conductors within the second axial passage. 24.The method of claim 22, wherein the inner insulator includes a firstinner insulator portion and a second inner insulator portion, the methodfurther comprising the step of: joining the first inner insulatorportion to the second inner insulator portion, thereby disposing theinner insulator and the first, second, and third shield conductorswithin the first axial passage.
 25. A method of splicing shielded wirecables together, comprising the steps of: providing a first shieldedwire cable having a first core conductor at least partially axiallysurrounded by a first shield conductor which is at least partiallyaxially surrounded by a first insulative jacket; providing a secondshielded wire cable having a second core conductor at least partiallyaxially surrounded by a second shield conductor which is at leastpartially axially surrounded by a second insulative jacket; providing athird shielded wire cable having a third core conductor at leastpartially axially surrounded by a third shield conductor which is atleast partially axially surrounded by a third insulative jacket;providing a shield defining a longitudinal axis, a first axial passage,and a first, second, and third contact configured to be electricallyconnected to the first, second, and third shield conductor respectively,said shield formed of a conductive material; providing an innerinsulator defining a second axial passage, said inner insulator formedof a dielectric material; joining the first core conductor to the secondcore conductor and the third core conductor; disposing the joined first,second, and third inner conductors within the second axial passage;disposing the inner insulator and the first, second, and third shieldconductors within the first axial passage, wherein portions of the ofthe first, second, and third shield conductors disposed within the innerinsulator are substantially parallel to the longitudinal axis;separating the first, second, and third insulative jackets one fromanother; attaching the first contact to the first shield conductor, thesecond contact to the second shield conductor, and the third contact tothe third shield conductor, thereby providing a conductive path betweenthe first, second, and third shield conductors; providing an outerinsulator formed of a nonconductive material; disposing the shieldwithin the outer insulator; and sealably engaging the outer insulator tothe first, second, and third insulative jackets, thereby enclosing theshield within the outer insulator, wherein the outer insulator furtherincludes an end cap configured to sealably engage the outer insulatorand at least one shielded wire cable and wherein the method furthercomprises the steps of sealably engaging the end cap with the at leastone shielded wire cable, and sealably engaging the end cap with theouter insulator, thereby enclosing the shield within the outerinsulator.
 26. A system, comprising: a battery pack having a firstterminal and a second terminal; a first and a second electrical loadelectrically coupled to the battery pack; a first wire harness assemblyincluding a first shielded wire cable having a first core conductor atleast partially axially surrounded by a first shield conductor which isat least partially axially surrounded by a first insulative jacket, asecond shielded wire cable having a second core conductor at leastpartially axially surrounded by a second shield conductor which is atleast partially axially surrounded by a second insulative jacket; athird shielded wire cable having a third core conductor at leastpartially axially surrounded by a third shield conductor which is atleast partially axially surrounded by a third insulative jacket, whereinthe first, second and third core conductors are directly joined and thefirst, second, and third shield conductors are electrical coupled to oneanother, wherein the first shielded wire cable is connected to the firstterminal, the second shielded wire cable is connected to the firstelectrical load, and the third shielded wire cable is connected to thesecond electrical load; a second wire harness assembly including afourth shielded wire cable having a fourth core conductor at leastpartially axially surrounded by a fourth shield conductor which is atleast partially axially surrounded by a fourth insulative jacket, afifth shielded wire cable having a fifth core conductor at leastpartially axially surrounded by a fifth shield conductor which is atleast partially axially surrounded by a fifth insulative jacket; a sixthshielded wire cable having a sixth core conductor at least partiallyaxially surrounded by a sixth shield conductor which is at leastpartially axially surrounded by a sixth insulative jacket, wherein thefourth, fifth, and sixth core conductors are directly joined and thefourth, fifth, and sixth shield conductors are electrical coupled to oneanother, wherein the fourth shielded wire cable is connected to thesecond terminal via a fusible link, the fifth shielded wire cable isconnected to the first electrical load, and the sixth shielded wirecable-is connected to the second electrical load and a controller incommunication with the first and second electrical load and configuredto control the first and second electrical load so that a currentflowing through the fourth shielded wire cable is less than a thresholdrequired to open the fusible link.
 27. The system of claim 26, whereineach pair of first and second wire harness assemblies are connected toonly one fusible link.